Description:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to a multilevel management system, and more specifically, relates to a system for multilevel sensing in containers.

BACKGROUND
[0002] In conventional level detection systems, several approaches are employed to address the challenge of synchronizing multiple apparatus or detecting liquid levels. One common approach involves the use of synchronization input (sync IN) and output (sync OUT) signals, which require additional wiring between the apparatus for effective operation. While this method provides synchronization, it introduces significant limitations, including increased installation complexity, higher costs due to the need for extra wiring and circuits, and reduced reliability stemming from the dependency on additional hardware interconnections.
[0003] Another prevalent method involves the use of float switch mechanisms to detect multiple levels. Although this approach is widely adopted, it suffers from several drawbacks, particularly in applications involving turbulent fluids or environments with significant vibrations. Under such conditions, the float switches are prone to false readings, mechanical damage, or operational failures. Additionally, float switches have inherent maintenance challenges, including periodic replacement due to wear and tear, susceptibility to rust and fouling, and deterioration of the exposed moving parts. These issues can lead to unreliable performance, clogging, or seizure of the float actuation mechanism, resulting in extended downtime and cumbersome installation procedures.
[0004] Further, in the existing system depicted in FIG. 1, filling and emptying a container is disclosed. System 100 includes a first control apparatus 102-1, a second control apparatus 102-2, a container 104, and one or more level probes 106. The first control apparatus 102-1 is responsible for filling container 104, while the second control apparatus 102-2 is responsible for emptying the container. The level probes 106 of both the first and second apparatuses are immersed in container 104, where the liquid levels are monitored and controlled. The level probes 106 are sensors immersed in container 104 to detect the liquid level. The reference ground connection (REF) serves as a shared ground. The electrical interconnections and protective earth (PE) grounding are implemented to ensure proper electrical functionality and adherence to safety standards. However, the level probe excitation signal operates at a fixed frequency that is not synchronized with the power input line frequency. Consequently, when the level probes of multiple apparatuses are immersed in a container, interference arises between the excitation signals, resulting in operational malfunctions in each apparatus.
[0005] Therefore, there exists a need for an improved level detection system that eliminates the requirement for inter-apparatus wiring and mitigates the challenges associated with float switch mechanisms, ensuring reliable, efficient, and maintenance-free operation in diverse environments.

OBJECTS OF THE PRESENT DISCLOSURE
[0006] An object of the present disclosure is to provide a system that ensures quick and efficient installation in the field.
[0007] Another object of the present disclosure is to provide a system that reduces product cost by eliminating the need for synchronization input/output circuits and connectors.
[0008] Another object of the present disclosure is to provide a system with enhanced reliability achieved through reduced wiring and circuit complexity.
[0009] Another object of the present disclosure is to provide a system that can be easily retrofitted into existing installations.
[0010] Another object of the present disclosure is to provide a system that eliminates moving parts, thereby avoiding wear and tear.
[0011] Another object of the present disclosure is to provide a system that can be easily upgraded for varying levels without requiring configuration or reprogramming.
[0012] Yet another object of the present disclosure is to provide a system with individual control relays for each device, enabling independent operation of pumps or valves and allowing logical combinations for controlling shared pumps or valves.
SUMMARY
[0013] The present disclosure in general, to a multilevel management system, and more specifically, relates to a system for multilevel sensing in containers. The main objective of the present disclosure is to overcome the drawbacks, limitations, and shortcomings of the existing system and solution, by providing a system in which the level probe is excited in synchronization with the AC power input line frequency. This configuration ensures that the excitation signals of multiple apparatuses are synchronized, enabling each apparatus to function independently without disrupting the operation of neighboring apparatuses.
[0014] The present disclosure provides a system for multilevel sensing in containers includes at least two control apparatuses, including a first control apparatus and a second control apparatus, each configured to regulate multiple levels within a container. The system includes a plurality of level probes, each positioned at predetermined levels within the container to detect multiple levels within the container. A zero-crossing detector is integrated within each of the at least two control apparatuses, where the zero-crossing detector is configured to detect a zero-crossing point of AC power input signals and generate electrical signals. The AC power input signals are received by both the first control apparatus and the second control apparatus. The zero-crossing detector operates with a predefined input voltage range of 20.4 to 264 Vac, a predefined input frequency range of 45 to 65 Hz, and a predefined AC input voltage waveform with harmonic distortion. The zero-crossing detector may be used in combination with an opto-isolator for both zero-crossing detection and power failure detection.
[0015] The system further includes a set of terminals electrically coupled to corresponding level probes to excite the level probes and a microcontroller integrated within each of the at least two control apparatuses. The microcontroller is coupled to the respective zero-crossing detector and the set of terminals. The microcontroller is configured to receive the electrical signals from the zero-crossing detector and generate square wave signals on the set of terminals to serve as excitation signals for the plurality of level probes. The square wave signals on the set of terminals are synchronized with the AC power input signals. The microcontroller excites the corresponding level probes in the container to provide information about multiple levels. The excitation signals of the plurality of level probes in at least two control apparatuses are synchronized with the AC power input signals to mitigate interference, facilitating independent operation both within and between the first control apparatus and the second control apparatus. Therefore, the system allows for quick installation in the field, significantly minimizing downtime. The system is cost-effective, as it eliminates the need for synchronization IN/OUT circuits and their associated connectors. By reducing the amount of wiring and circuitry, the system ensures high reliability. Additionally, the system can be easily retrofitted into existing installations, offering flexibility and seamless integration.
[0016] The level probes are configured to detect predetermined levels, such levels including a top level, an intermediate level, a low level, or any combination thereof. The level probes are excited by excitation signals synchronized with the AC power input signals, ensuring independent and interference-free operation of the first and second control apparatuses, even when powered at different intervals.
[0017] Further, the set of terminals includes a first set of terminals and a second set of terminals. The first control apparatus is coupled to the first set of terminals, and the second control apparatus is coupled to the second set of terminals. The first and second sets of terminals are connected to the corresponding level probes to transmit the excitation signals generated by the microcontroller integrated within each control apparatus. The terminals include at least two terminals coupled to corresponding level probes positioned at distinct levels within the container, such as the top level and the intermediate level. The plurality of level probes includes a common level probe coupled to at least one terminal from both the first and second sets of terminals. The common level probe is positioned at the low level within the container. Therefore, with no moving parts, wear and tear is eliminated, thereby enhancing the durability. Furthermore, the system is easily upgradeable to varying levels without the need for configuration or reprogramming.
[0018] Moreover, the system includes a relay coupled to the respective microcontroller, enabling the independent operation of a pump or a valve. The first control apparatus is configured to regulate the multiple levels within the container by activating or deactivating the pump operatively coupled to an inlet of the container. The second control apparatus is configured to regulate the multiple levels within the container by opening or closing the valve operatively coupled to an outlet of the container. Therefore, the system provides individual control relays for each apparatus, enabling the independent operation of pumps or valves. Additionally, the system allows for any logical combination of controls to be applied, facilitating the efficient management of a common pump or valve.
[0019] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The following drawings form part of the present specification and are included to further illustrate aspects of the present disclosure. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0021] FIG. 1 illustrates a schematic view of an existing system for filling and emptying a container.
[0022] FIG. 2 illustrates an exemplary view of a system for controlling multiple levels in a shared container, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0023] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0024] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0025] The present disclosure provides a system featuring a multilevel capability designed to monitor and control more than two levels within a container. For applications requiring control of two levels, a single control apparatus without the multilevel feature suffices. However, when monitoring and controlling four, six, eight, or more levels, the control apparatus with the multilevel feature is employed. In such configurations, two control apparatuses with the multilevel feature are utilized for four levels, three control apparatuses for six levels, and additional control apparatuses are incrementally added for higher-level monitoring and control. The control apparatus synchronizes the excitation signals of its level probes with the AC power input line frequency, enabling each probe to operate independently without interference, even in a shared container environment. This synchronization eliminates the need for additional wiring for signal alignment, reducing installation complexity, associated costs, and potential failure points.
[0026] The system operates across a broad range of input voltages, from 20.4 Vac to 265 Vac, and supports line frequencies from 45 Hz to 65 Hz. It is capable of reliable operation even under poor power quality conditions, including harmonic distortions spanning from the 3rd to the 23rd harmonic. The control apparatus ensures synchronized probe excitation, maintaining operational reliability even if individual units are powered on at different times.
[0027] In an aspect, the apparatus can include at least two control apparatuses managing multiple levels in the container, with each control apparatus featuring three terminals connected to metal rods or probes immersed at varying levels within the container. The shared metal rod, connected to both control apparatuses, is positioned at the lowest level in the container. Each control apparatus generates synchronized square wave signals on its terminals through the microcontroller equipped with a zero-crossing detection (ZCD) mechanism that aligns the square wave generation with the AC power input sine wave. The synchronization of square waves across all control apparatuses sharing the common AC power input prevents malfunction due to misalignment, thereby ensuring reliable multilevel monitoring and control. The present disclosure enables robust, interference-free operation in complex multilevel management systems. The present disclosure can be described in enabling detail in the following examples, which may represent more than one embodiment of the present disclosure.
[0028] The advantages achieved by the system of the present disclosure can be clear from the embodiments provided herein. The system enables precise and reliable monitoring of multiple levels in a container, vessel, or tank. It supports the synchronization of excitation signals across multiple control apparatuses, preventing interference and ensuring the independent operation of each apparatus. The system may be suitable for diverse industrial and environmental applications. The system is capable of operating under varying power conditions, with the synchronization algorithm designed to function reliably even with fluctuations in line voltage, frequency, and harmonic distortion. Additionally, it supports easy integration with existing container systems by allowing flexible positioning of level probes at multiple predefined heights, optimizing the control of levels across various containers. Furthermore, the system eliminates the need for synchronous power-on, allowing the control apparatuses to operate independently, even when powered on at different times, ensuring seamless functionality. The description of terms and features related to the present disclosure shall be clear from the embodiments that are illustrated and described; however, the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents of the embodiments are possible within the scope of the present disclosure. Additionally, the invention can include other embodiments that are within the scope of the claims but are not described in detail with respect to the following description.
[0029] FIG. 2 illustrates an exemplary view of a system for controlling multiple levels in a shared container, in accordance with an embodiment of the present disclosure.
[0030] Referring to FIG. 2, system 200 for controlling multiple levels in a shared container or tank using multiple control apparatuses is disclosed. The system 200 can include control apparatuses (202-1, 202-2), zero-crossing detector (ZCD) (204-1, 204-2 (which are collectively referred to as zero-crossing detector 204, herein)), a set of terminals (206-1 to 206-6), a microcontroller (208-1, 208-2 (which are collectively referred to as microcontroller 208, herein)), a container 210 and a plurality of level probes (212-1 to 212-5).
[0031] In an embodiment, system 200 includes at least two control apparatuses including a first control apparatus 202-1 and a second control apparatus 202-2, each configured to regulate multiple levels within container 210. In an exemplary embodiment, the first control apparatus 202-1 and the second control apparatus 202-2, as presented in the example, can be liquid level controller (LLC) apparatus, each configured with a multilevel sensing capability. As can be appreciated, the present disclosure is not limited to the liquid level controller (LLC) product and may be applied to a wide range of other industry and applications such as chemical processing plants, pharmaceutical manufacturing, food and beverage industry, oil and gas industry and other similar fields. The system 200 as shown in FIG. 2 is configured to control the level of fluids, the fluids are selected from a group including a liquid, a semi-liquid, or any combination thereof. The present disclosure applies to liquids with resistivity ranging from 250 Ohms to 1 Mega Ohm. Examples of such liquids include seawater with low resistivity, which is highly conductive, and distilled water with high resistivity, which is highly resistive. Other examples within this range may include tap water, brine solutions, and industrial process fluids, each varying in resistivity depending on their mineral content and composition. FIG. 2 disclosed herein are merely illustrative and provided to facilitate the understanding of the liquid level controller. However, the illustrations are not intended to limit the scope of the invention and are exemplary representations of one or more embodiments.
[0032] In an embodiment, the first control apparatus 202-1 and the second control apparatus 202-2, each configured to regulate multiple levels within the container 210. The system 200 requires control of two levels, a single control apparatus without the multilevel feature suffices. However, when monitoring and controlling four, six, eight, or more levels, the control apparatus with the multilevel feature is employed. In such configurations, two control apparatuses with the multilevel feature are utilized for four levels, three control apparatuses for six levels, and additional control apparatuses are incrementally added for higher-level monitoring and control. The control apparatus synchronizes the excitation signals of its level probes with the AC power input line frequency, enabling each probe to operate independently without interference, even in a shared container environment. This synchronization eliminates the need for additional wiring for signal alignment, reducing installation complexity, associated costs, and potential failure points.
[0033] In another embodiment, each control apparatus 202 is equipped with a zero-crossing detector (ZCD) 204 to detect the zero-crossing points of the AC power input sine wave 214 (also referred to as AC power input signals). The term zero-crossing points refers to the moments in a sinusoidal waveform (such as an AC power signal) when the signal's value crosses zero, i.e., when the waveform transitions from positive to negative or negative to positive. The zero-crossing detector 204 integrated within each of the at least two control apparatuses 202, the zero-crossing detector 204 is configured to detect a zero-crossing point of the AC power input signals and generate electrical signals, where the AC power input signals are received by both the first control apparatus 202-1 and the second control apparatus 202-2. The zero-crossing detector 204 of the first and second control apparatuses is configured to filter noise from the AC power input signal before transmitting the electrical signal to the respective microcontrollers. The zero-crossing detector 204 is used in combination with an opto-isolator for both zero-crossing detection and power failure detection.
[0034] Each of the first control apparatus 202-1 and the second control apparatus 202-2 includes the microcontroller (208-1, 208-2). The microcontroller 208 in each control apparatus is coupled to the corresponding zero-crossing detector 204, where the microcontroller 208 generates synchronized square wave signals based on the zero-crossing detection. A common AC power input 214 is provided to supply both control apparatuses. The AC power input is common to both control apparatuses, ensuring that the sinewave 216 serves as a common reference for synchronization. The microcontroller (208-1, 208-2) integrated within each of the at least two control apparatuses, coupled to the respective zero-crossing detector 204, the microcontroller configured to receive the electrical signal from the zero-crossing detector and generate square wave signals to serve as excitation signals.
[0035] The microcontroller (208-1, 208-2) executes a synchronization algorithm configured to ensure reliable operation under adverse power conditions. The algorithm accommodates a wide range of line voltage, line frequency, and harmonic distortions, enabling the product to operate effectively in diverse geographical locations. Specifically:
• Line Voltage: Supports universal supply voltage ranging from 20.4 Vac to 265 Vac.
• Line Frequency: Supports universal power frequency in the range of 45 Hz to 65 Hz.
• Line Harmonics: Handles harmonic distortions from the 3rd to the 23rd harmonic, ensuring functionality under severe distortion conditions.
• Turn-On Timing: Operates without requiring synchronous power-on, enabling reliable performance even when units are powered on at different times.
[0036] The microcontroller 208 in communication with the zero-crossing detector 204 generates synchronized excitation signals for the level probes (212-1 to 212-5), enabling independent operation of the control apparatuses. The synchronization of the excitation signals with the AC power input signal prevents interference between the filling and emptying operations, ensuring robust and reliable system performance even under conditions of variable content resistivity or fluctuating power supply. The microcontroller (208-1, 208-2) executes the synchronization algorithm to align the excitation frequencies with the AC power input line frequency, ensuring robust and interference-free operation across diverse power conditions.
[0037] The plurality of level probes (212-1 to 212-5), each positioned at predetermined levels within the container 210. The predetermined levels pertaining to a top-level, intermediate level, a low level and any combination thereof. The plurality of level probes (212-1 to 212-5) are positioned at distinct levels within the container 210, where a top-level probe detects when the container is full, a middle-level probe monitors intermediate level, and low-level probe detects when the container is nearly empty.
[0038] In an exemplary embodiment, the plurality of level probes (212-1 to 212-5) may include metal rods designed to sense the level at various points within the container. The level probes (212-1 to 212-5) of the first control apparatus 202-1 and the second control apparatus 202-2 are deployed within the container 210 and are configured to function independently without mutual interference. The independent operation is facilitated by synchronizing the excitation frequencies of the level probes (212-1 to 212-5) in both apparatuses (202-1, 202-2) with the AC power input line frequency, thereby eliminating cross-coupling or signal disruption between the apparatuses.
[0039] In an embodiment, the set of terminals (206-1 to 206-6) coupled to respective microcontroller 208, the set of terminals configured to electrically connect to corresponding level probes (212-1 to 212-5) and transmit the excitation signals to the corresponding level probes in the common container to provide information about the levels, where the excitation signals are synchronized with the AC power input signals to mitigate interference between the first control apparatus 202-1 and the second control apparatus 202-2 so as to enable independent operation of the first control apparatus and the second control apparatus.
[0040] In an exemplary embodiment, the set of terminals (206-1 to 206-6) can include a first set of terminals (206-1 to 206-3) and a second set of terminals (206-4 to 206-6). The first set of terminals (206-1 to 206-3) is associated with the first control apparatus 202-1 for connecting to the corresponding level probes (212-1, 212-2, and 212-5), respectively. Similarly, the second set of terminals (206-4 to 206-6) is associated with the second control apparatus 202-2 for connecting to the corresponding level probes (212-3, 212-4, and 212-5), respectively. The first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6) are connected to the corresponding level probes to transmit the square wave signals generated by the respective microcontrollers.
[0041] In one embodiment, the first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6) can include at least two terminals (206-1, 206-2, 206-4, 106-5) coupled to corresponding level probes (212-1 to 212-4) positioned at distinct levels pertaining to the top level and the intermediate level within the container 210. In another embodiment, the plurality of level probes (212-1 to 212-5) includes a common level probe (212-5) that is coupled to at least one terminal (206-3, 206-6) from both the first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6), the common level probe (212-5) positioned at the low level within the container 210.
[0042] The microcontroller 208 in both the first control apparatus 202-1 and the second control apparatus 202-2 is connected to corresponding relays (226-1, 226-2(which are collectively referred to as relay 226, herein)). The relay 226 switches external devices (e.g., pumps) ON/OFF to maintain the levels within the desired range. The relay 226 possibly triggers a mechanism to regulate filling/draining when the level reaches the minimum or maximum points. For example, in an exemplary embodiment, the first control apparatus 202-1 is configured to activate a pump to add content when the level within the container 210 reaches a predefined low level and deactivate the pump when the level reaches a predefined high level. Similarly, the second control apparatus 202-1 is configured to activate a valve to release content when the level within container 210 reaches the predefined high level and close the valve when the level reaches a predefined low level.
[0043] In an implementation of an embodiment, the present disclosure as presented in the example can include two control apparatuses with the multilevel feature utilized for four levels. The first control apparatus 202-1 includes the zero-crossing detector (ZCD) 204-1 configured to detect the zero-crossing point of the AC power input sine wave 216 and transmit the electrical signal to the microcontroller 208-1. The microcontroller 208-1, coupled to the ZCD 204-1, generates square wave signals on the first set of terminals (206-1 to 206-2) connected to corresponding level probes (212-1, 212-2). The level probes (212-1, 212-2) are positioned at specific levels within the container 210 to monitor levels. Additionally, the level probe 212-5, connected to at least one terminal 206-3 of the first set of terminals (206-1 to 206-3), is positioned at the lowest level of the container 210. The microcontroller 208-1 generates square wave signals (218, 220) at the terminals (206-1, 206-2) in precise synchronization with the AC sine wave 216, ensuring accurate operation.
[0044] Similarly, the second control apparatus 202-2 includes the zero-crossing detector (ZCD) 204-2 configured to detect the zero-crossing point of the AC power input sine wave 216 and transmit the electrical signal to the microcontroller 208-2. The microcontroller 208-2, coupled to the ZCD 204-2, generates square wave signals on the second set of terminals (206-4, 206-5) connected to corresponding level probes (212-3, 212-4). The level probes (212-3, 212-4, 212-5) are positioned at specific levels within the container 210 to monitor levels. Additionally, the level probe 212-5, connected to at least one terminal 206-6 of the second set of terminals, is positioned at the lowest level of the container 210. The microcontroller 208-2 generates square wave signals (222, 224) at the terminals (206-4, 206-5) in precise synchronization with the AC sine wave 216, ensuring accurate operation.
[0045] The system ensures proper operation by synchronizing the square wave signals generated by both control apparatuses (202-1, 202-2) with the AC sinewave 216. This synchronization is critical because, if the square wave signals at the terminals (206-1, 206-2, 206-4, 206-5) are not aligned, the control apparatuses (202-1, 202-2) may interfere with each other, leading to operational failure. The design of system 200 ensures robust and reliable level control in the shared container, vessel or tank, even under challenging operating conditions.
[0046] For example, the present disclosure provides the system 200 for managing multiple levels in a shared container or tank, such as a large container used in industrial processes, where maintaining the level within specific limits is critical to prevent overflows or drying out. The system 200 includes two control apparatuses (202-1, 202-2) for filling and emptying. One control apparatus activates a pump when the level drops to the bottom-level probe and deactivates the pump when the level reaches the middle or top-level probe based on the desired fill level. The other control apparatus activates a valve when the level reaches the top-level probe and closes the valve when the level drops to the middle or bottom-level probe, depending on the required emptying level.
[0047] The system employs level probes (212-1 to 212-5), which are metal rods positioned at different levels in the container 210 to detect levels, where the top-level probes (e.g., 212-1, 212-2) detect when the container is full, the middle-level probes (e.g., 212-3, 212-4) monitor intermediate levels, and the low -level probe (212-5) detects when the container is nearly empty. To ensure synchronized operation, the system 200 includes the zero-crossing detector (ZCD) 204 and the microcontroller 208 in each control apparatus 202 to enable synchronization of the excitation signals of level probes (212-1 to 212-5) with the AC power input line frequency, enabling each probe to operate independently without interference from others, even when used in common container 210. The system ensures robust and reliable performance, preventing overflows, pump failures, or valve malfunctions, even under challenging conditions such as fluctuating power supply or varying content resistivity.
[0048] Thus, the present invention overcomes the drawbacks, shortcomings, and limitations associated with existing solutions, and provides the system that enables precise and reliable monitoring of multiple levels in the container, vessel, or tank. It supports the synchronization of excitation signals across multiple control apparatuses, preventing interference and ensuring the independent operation of each apparatus. The system may be suitable for diverse industrial and environmental applications. The system is capable of operating under varying power conditions, with the synchronization algorithm designed to function reliably even with fluctuations in line voltage, frequency, and harmonic distortion. Additionally, it supports easy integration with existing container systems by allowing flexible positioning of level probes at multiple predefined heights, optimizing the control of levels across various containers. Furthermore, the system eliminates the need for synchronous power-on, allowing the control apparatuses to operate independently, even when powered on at different times, ensuring seamless functionality.
[0049] It will be apparent to those skilled in the art that system 200 of the disclosure may be provided using some or all of the mentioned features and components without departing from the scope of the present disclosure. While various embodiments of the present disclosure have been illustrated and described herein, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE PRESENT INVENTION
[0050] The present disclosure provides a system that enables precise and reliable monitoring of multiple levels in a container, vessel, or tank.
[0051] The present disclosure provides a system that supports the synchronization of excitation signals across multiple control apparatuses, preventing interference and ensuring the independent operation of each apparatus.
[0052] The present disclosure provides a system may be suitable for diverse industrial and environmental applications.
[0053] The present disclosure provides a system that is capable of operating under varying power conditions, with the synchronization algorithm designed to function reliably even with fluctuations in line voltage, frequency, and harmonic distortion.
[0054] The present disclosure provides a system that supports easy integration with existing container systems by allowing for flexible positioning of level probes at multiple predefined heights, thus optimizing the control of levels across various containers.
[0055] The present disclosure provides a system that eliminates the need for synchronous power-on, allowing the control apparatuses to operate independently, even when powered on at different times, ensuring seamless functionality.
, Claims:1. A system (200) for controlling a plurality of levels within a container, the system comprising:
at least two control apparatuses (202-1, 202-2), comprising a first control apparatus (202-1) and a second control apparatus (202-2), each configured to regulate the plurality of levels within the container (210);
a plurality of level probes (212-1 to 212-5), each positioned at predetermined levels within the container (210);
a zero-crossing detector (ZCD) (204) integrated within each of the at least two control apparatuses (202-1, 202-2), the zero-crossing detector (204) configured to detect a zero-crossing point of AC power input signals and generate electrical signals, wherein the AC power input signals are received by both the first control apparatus (202-1) and the second control apparatus (202-2);
a set of terminals (206-1 to 206-6) electrically coupled to corresponding level probes to excite the corresponding level probes; and
a microcontroller (208) integrated within each of the at least two control apparatuses (202-1, 202-2), coupled to the respective zero-crossing detector (204) and the set of terminals (206-1 to 206-6), the microcontroller (208) configured to:
receive the electrical signals from the zero-crossing detector (204);
generate square wave signals on the set of terminals to serve as excitation signals for the plurality of level probes (212-1 to 212-5), wherein the square wave signals on the set of terminals (206-1, 206-2, 206-4, 206-5) are synchronized with the AC power input signals; and
excite the corresponding level probes (212-1 to 212-5) in the container (210) to provide information about the predetermined levels, wherein the excitation signals of the plurality of level probes in the at least two control apparatuses (202-1, 202-2) are synchronized with the AC power input signals to mitigate interference so as to facilitate independent operation both within and between the first control apparatus (202-1) and the second control apparatus (202-2).
2. The system as claimed in claim 1, wherein the plurality of level probes (212-1 to 212-5) configured to detect the predetermined levels, the predetermined levels pertaining to a top level, an intermediate level, a low level and any combination thereof.
3. The system as claimed in claim 1, wherein the plurality of level probes (212-1 to 212-5) excited by the excitation signals synchronized with the AC power input signals, wherein the synchronization of the excitation signals with the AC power input signals ensures independent and interference-free operation of the first control apparatus (202-1) and the second control apparatus (202-2), even when the first control apparatus (202-1) and the second control apparatus (202-2) are powered at different intervals.
4. The system as claimed in claim 1, wherein the set of terminals (206-1 to 206-6) comprises a first set of terminals (206-1 to 206-3) and a second set of terminals (206-4 to 206-6), wherein the first control apparatus (202-1) coupled to the first set of terminals (206-1 to 206-3) and the second control apparatus coupled to the second set of terminals (206-4 to 206-6), wherein the first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6) connected to the corresponding level probes (212-1 to 212-5) to transmit the excitation signals generated by the microcontroller (208) integrated within each of the at least two control apparatuses.
5. The system as claimed in claim 4, wherein the first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6) each comprise at least two terminals (206-1, 206-2, 206-4, 206-5) coupled to the corresponding level probes (212-1 to 212-4) positioned at distinct levels pertaining to the top level and the intermediate level within the container (210).
6. The system as claimed in claim 1, wherein the plurality of level probes (212-1 to 212-5) comprises a common level probe (212-5) that is coupled to at least one terminal (206-3, 206-6) from both the first set of terminals (206-1 to 206-3) and the second set of terminals (206-4 to 206-6), the common level probe (212-5) positioned at the low level within the container (210).
7. The system as claimed in claim 1, wherein the system comprises:
a relay (226) coupled to the respective microcontroller (208), enabling independent operation of a pump or a valve, wherein:
the first control apparatus (202-1) is configured to regulate the plurality of levels within the container (210) by activating or deactivating the pump, the pump is operatively coupled to an inlet of the container; and
the second control apparatus (202-2) is configured to regulate the plurality of levels within the container by opening or closing the valve, the valve is operatively coupled to an outlet of the container (210);
8. The system as claimed in claim 1, wherein the zero-crossing detector (ZCD) (204) is configured to operate with a predefined input voltage range of 20.4 to 264 Vac, a predefined input frequency range of 45 to 65 Hz and a predefined AC input voltage waveform with harmonic distortion.
9. The system as claimed in claim 1, wherein the zero-crossing detector (ZCD) (204) is used in combination with an opto-isolator for both zero-crossing detection and power failure detection.